78E Exhaust rebuild

[Radioguylogs]

I'm fascinated by the penetrating oil test results.

Thanks for posting it Brian!

[dbbrian]

This is something (I believe) everyone should do. Unlike others, I personally prefer to use the paper gaskets (just a personal preference).

KURT

I like them too Kurt. Not that I have any good reason to , just nostalgic for original ways and the 70's

I have the header crush ring gaskets and valve cover gasket (parts-n-more) but no pan gasket yet.

Thanks for the tip on the engine set.

[dbbrian]

Brian, some or maybe all of the aftermarket exhausts were configured for the mufflers to slip on/off. Thus, four separate header pipes. After a number of years assembled, it normally requires oxy/acetylene heat to separate them.

I believe it is a patch job on original exhaust components. Time will tell what is going once I can buy a hex key socket set and apply to those exhaust stud nuts..

[DiverRay]

Hit the nuts with homebrew before trying to loosen them! a bit of ATF/Acetone will help loosen up the years of rust.

[dbbrian]

50 - 50

50% success.

Weeks of applying Liquid Wrench seemed to work on pipes 3 and 4, they gave up the nuts fairly easy, not much effort at all.

Similar effort on pipes 1 & 2 took the studs out with the nuts. At least they came out without breaking studs off

On re-assembly, do I just leave the nuts on the studs and put them back in like a regular bolt?

Brian

[motoman]

Brian, I highly recommend nuts be removed and studs screwed in seperately as those holes are bottom holes. Screw studs in, and to snug them down double nut the stud, tighten stud, remove double nut.

[dbbrian]

4 Connectors!

I have 4 connectors, all seem identical, other than the bolt head on the outer two are slightly smaller. Try the link for a few pics

https://photos.app.goo.gl/9a8eyioRb83uSNb4A

The parts diagram for the exhaust system show only two part #12 exhaust gaskets. It does not show one in the cross connector, but the pipe dimensions measure the same and appears to have one, so I figure 5th one.

One pipe is missing the gasket, explains the soot at the joint. The others seem lodged in there pretty good. Any tricks to remove?

So it seems I need 5 gaskets. Found some on Parts n More for 1/3 the cheapeest price anywhere else. Bonus for me is no shipping - they distribute from my home town. I have made a few purchases there and been satisfied.
They seem to have more parts for our bikes than what shows up if you sort by XS1100. I searched by part number.

Also, no idea why there is a pipe clamp on the back edge of ther decorative chome shield. It is welded onto the pipe.

Part'n'More https://www.partsnmore.com/parts/yam...muffler+gasket

[dbbrian]

Need an oil pan gasket

Think I'll just order the one (missing) gasket and leave the others in place.

Anyone have an oil pan gasket? I don't want to buy the whole set of engine gaskets to get just the one I need, and would like to use one, not just the goop.


Brian

[bikerphil]

Ebay sells them separate you know, I don't know about shipping fees to Canada though. They are pretty simple to make with an X-acto and a hole punch with some thick gasket paper from auto parts. Take the splash guards off the inside of the oil pan so it can lay flat on the paper.

[dbbrian]

Nuts and bolts

I picked up a set of the Dorman 03411 exhuast stud bolts - found the reference to them on this site.

They are slightly longer than the originals, but have an extension past the threads that you can put a wrench on to tightren the bolt.

Original hex nuts and the new ones in the Dorman set will not go onto either original or new studs more than the thickness of the nut. I thought it was a mis-match of threads and nuts at first, but it seems something stops them. No combination of nut and bolt, new or old changes this.

Anyone have exerience with this?

Brian

[DiverRay]

All exhaust nuts are "deformed" so they lock in place. It should ALWAYS take a wrench to install them. If not, replace the nuts because they will vibrate loose.

[dbbrian]

Exhaust studs and connector gaskets

Exhaust Studs for 78E

The Dorman 03411 are too long. Not for the 78E I guess, unless you use the nuts that come with them and not the hex head nuts that are original to the bike.

I like the idea of keeping it original, so I cleaned up the nuts with a vinegar soak overnight, and treated them to phosoric acid to halt future rust. Thy look like new.

I searched the Dorman site and found that Dorman 03415B are closer at 40mm to my studs at 41 - 41mm. The auto parts store didn't have them, but Dorman noted the vehicles they fit - several late 90's honda cars. So I went to the local honda dealer who had them in stock, but not as a Dorman product number.


Exhaust connector gaskets

Part #12 on the parts diagram - pulled out the old one at the leaky connection and it has a copper edge wrap on both edges of the cylinder sleeve gasket. Never noticed until I deformed the pieces of copper...the sleeve was baked into the spot and came out in pieces, but it came out thankfully.

Looking at the other three connectors, it appears at least two have the copper wrap as well. I think one does not. The replacement piece I got from Parts-N-More does not.

I hope it isn't important, thinking the originals were made of something different and required the coppper wrapped edges.

Anyone esle notice this?

Brian

[Radioguylogs]

The original gaskets in my XS bike exhausts seemed to be solid copper with some kind of cloth sheath. (asbestos? )

The replacements are a dark gray, flat material; coiled like a roll of tape.

[dbbrian]

Fully assembled

MximPhil dropped by to ensure the re-assembly would be complete and I owe him a drunken night of beer!

Loys of futzing and farting and cursing, but the oil pan and exhaust are back on the bike - the exhaust looks a lot better Grinding off loose rust with a brass wheel brush on the drill revealed 5 holes. I had them brazed. Used phosporic acid on the rust with wire brush. Some polising to finish.

Three Bond was used for sticking a Felpro hand cut paper gasket to the the oil pan. One of the oil pan bolts was very difficult, but persistence prevailed. There are 4 bolts longer than the others in the oil pan...those go along the front / oil filter side of the bike (glad I kept track on removal).

The crush gaskets came out eventualy, care of Phil and his assorment of tools (picks, pliers, swear words and beer)

The header bolts ended up being the Dorman 03415B. These are M8-1.25 x 40mm long. Not found in stock at the local car parts shop, but listed on Doorman's website as being for late 80's and 90's Honda cars, so I picked up mine from the local Honda dealer parts counter. Stock item for them. Dry fitting the headers with flanges determined the longer threaded end goes into the engine head. If you don't care to use the hex nuts, another bolt may work. Same for other year and model bikes.

Re-installing the back section of pipes was a two man job, alignment was tricky, and tiring.

The connector gasket from Parts N More fit great. Silver looking wrap on something or other.

Just need oil, gas, and to gently back the bike it out the side door of the house onto the deck for fairing re-install. Down the set of re-puposed roof-walkway sections turned into motorcycle ramps, and we will be off for some rides again!

Brian